Multi-Process Automation for India’s leading Gelatine Manufacturing Company
About the Client
A prominent player in the gelatine industry, the client manufactures pharmaceutical, edible, photographic and technical grades of gelatine for domestic and international markets.
Requirements
Gelatine manufacturing involves multiple interconnected and process-intensive stages where consistent control, sequencing, monitoring and coordination are critical. MIPL implemented an integrated automation solution covering key processes across the plant.
Scope of Automation
| Pit Automation | Automated aeration sequencing, pressure monitoring, alarms and stop/resume functionality across multiple pit groups. |
| Ion Exchange | Automated service, regeneration and CIP sequences for cation and anion columns, including chemical dosing, rinsing, alarms and interlocks. |
| Ultrafiltration (UF) | Automated feed, recirculation, permeate/reject control and CIP, with real-time monitoring of pressure, flow, conductivity and density. |
| APV Extraction | Automated extraction sequences from priming through production and flushing, with density-based control and integrated steam, vacuum and pump operations. |
| FFE Concentration | Automated multi-stage evaporation with vacuum, steam, condensate, liquor circulation and concentration monitoring. |
| Conditioner | Automated temperature and flow control using steam and chilled-water circuits, with energy recovery through a regenerator. |
| Sterilizer | Automated sterilization sequencing, temperature and vacuum control, flushing and QC tank selection with safety interlocks. |
| Dryer & Turbo Dryer | Automated multi-zone drying, conveyor speed, airflow and temperature control, along with product handling, cooling and safety systems. |
Integrated Control System
The plant processes are integrated through a Rockwell Automation-based control architecture, providing centralized monitoring and control across the major process sections. The distributed architecture incorporates redundant PLC and communication systems, remote I/O, HMIs and variable frequency drives.
Key Outcomes
Consistent Product Quality
Automated process control helps maintain consistency across soaking, extraction, concentration and drying.
Energy & Cost Efficiency
Optimized steam, vacuum, cooling and heat-recovery operations.
Operational Reliability
Automated sequences, alarms and interlocks improve process reliability.
Reduced Manual Intervention
Automated control and monitoring reduce operator dependency.
Traceability & Compliance
Centralized monitoring, historical data and audit trails support GMP requirements.
Scalable Automation
An integrated and modular architecture supports future plant expansion.
Why the Client Chose MIPL
Proven Expertise
30+ Years of experience in automation and control systems with a successful track record.
Quality & Innovation
Commitment to high standards, safety compliance, and use of advanced technologies.
Tailored Solutions
We provide customized automation strategies to meet unique client needs.